Cummins ISX Installation Manual Jan 2014 - airdogdiesel.com · 4G-HD FUEL PUMP, is a premium fuel filtration and delivery system for the Cummins ISX and Signature 600 Diesel Engines.

Providing “Test Cell Performance” in “Real World Conditions” Since 1993!

industrial

The Original Fuel Air Separation System

PROTECTED UNDER THE FOLLOWING PATENTS CANADA UNITED STATES OF AMERICA MEXICO 2,108,391 5,355,860; 5,746,184; 6,729,310 270409

NEW ZEALAND ITALY AUSTRALIA HONG KONG ECUADOR 532356 1362177 2005101054 1061420 PL10-2021 Additional Foreign Patents Issued and Pending in Europe, South America, Japan, and China!

Kit No. A3SPBT452

PLEASE READ THESE INSTRUCTIONS

THOROUGHLY BEFORE BEGINNING

INSTALLATION

INSTALLATION MANUAL For Trucks Equipped with

CUMMINS® Signature 600 & ISX Engines

NOW WITH DEMAND FLOW

2

THE RIGHT CHOICE FOR YOUR DIESEL ENGINE!New Design 4G-HD Fuel Pump (4th generation)

Pump Shaft, stabilized with bearings on each end, holds the Gerotor in virtually perfect alignment for quiet running and extended longevity!

New Quick Change Motor If necessary, the motor can be removed and replaced in a matter of minutes.

Water Separator/Prefilter Long Lasting Wire Mesh Media

6 Micron Particulate Filters Long Lasting MicroGlass Media

Positive Air Separation With Primary Air Discharge

Port

CARB Executive Orders No. D-595-1 & D-595U-1, permit the advertisement, sales, and installation in California of AirDog®, AirDog®II, Fuel Preporator®, and Fuel Preporator®II

Bearing

Protective Wire Screen In Water Separator Nipple!

●FPII-150 & FPII-200 8 ¼” W X 3 7/8” D X 12 ¾”T ● FPII-125 7” W X 3” D X 10” T●

Dual Port Pump Balances the Gerotor for Quiet Operation and Higher Flows!

Adjustable Regulator For Just the Right Fuel Demand Flow System!

Easy Installation, Only One Small Line Connected to the Engine Return Line to Return Air / Vapor to the Tank!

New Micro Processor Fuel Filter Monitor Lets you know when to Service the Fuel Filter & Water Separator before

suffering power loss NO MORE GUESSING!

industrial

3

SYSTEM OVERVIEW

Welcome to the AirDog® Fuel Preporator® Fuel Air Separation System for Class 8 Trucks

The AirDog®, with ADVANCED FUEL AIR SEPARATION, DEMAND FLOW, ADJUSTABLE REGULATOR, MICROPROCESSOR FILTER MONITOR and the NEW 4G-HD FUEL PUMP, is a premium fuel filtration and delivery system for the Cummins ISX and Signature 600 Diesel Engines. Air & Vapor are compressible! When Air/Vapor is present in a fuel injection system the pressure buildup and injection of fuel is delayed while the Air/Vapor is being compressed. This delay retards the injection timing causing a shorter power stroke and low power, increased fuel consumption and increased exhaust emissions. Preventing the formation of vapor from pump cavitation and removing entrained air from the fuel flow to the injectors restores Correct Injection Timing. Diesel engines equipped with the AirDog® can now perform as designed, delivering “test cell” performance while in “real world” use!

The AirDog® removes water, particulates and most importantly, the air that becomes entrained in diesel fuel, from the fuel flow to your engine. The entrained air and vapor that is separated from the fuel is returned to the fuel tank through a small return line. The fuel flow to the engine’s transfer pump is at a NET POSITIVE PRESSURE HEAD preventing cavitation and the formation of vapor thus overcoming the performance related problems from plugged fuel filters, high altitude operation and torque loss at higher engine RPM’s.

All AirDog® products are manufactured with a personal touch, unsurpassed attention to detail

and the most stringent quality assurance!

TYPICAL INSTALLATION LAYOUT

Figure 1 The AirDog® requires only one small return line connected to the engine return line, for quick and easy installations.

4

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 1 Table of Contents

TABLE OF CONTENTS Section 1……..……....………………….……..…....…..…...Table of Contents

Section 2……..…...…...............…...…..…Installation and Safety Guidelines

Section 3……..……...……….....…….…...……….……………....….Parts List

INSTALLATION PROCEDURES Section 4…….…….…..……….....…...Selecting the Best Mounting Location

Section 5………...…..…………...................…AirDog® & Mounting Brackets

Fuel Lines, Fittings & Low Fuel Pressure Sensor Switch

Section 6A...............................................................Fittings & Sensor Switch

Section 6B….….…..…....…..........................AirDog® Air/Vapor Return Line

Section 6C……..….....................................Fuel Line from Tank & to Engine

Electrical Harness

Section 7…..….……....…..……………..………....………..Electrical Harness

VERY IMPORTANT: The AirDog® electrical harness requires a MAXIMUM

15Amp Fuse!

Section 8..……….…..……….…………................….…….……Initial Start Up

Fuel Rail Pressure Section 9……………………………………..Checking the Fuel Rail Pressure

Maintenance Section 10..………...…….….……...........…Filter Service Recommendations

Section 11……………….…..........................Cleaning the Gerotor Assembly

Section 12.......................................................................Pressure Regulator

5

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 2 Installation & Safety Guidelines

The installation of your AirDog® can be made relatively easy by following the steps outlined in this manual, and: 1. Inventory the package components. Immediately notify PUREFLOW® Technologies, Inc., of any missing or damaged parts. 2. Read the installation manual completely. Understand how the system operates

and the installation recommendations before beginning.

3. Proper location of the AirDog® on the vehicle is essential. Consider hazards presented to the equipment by road debris and the elements.

4. The installation recommendations and guidelines contained herein are

suggestions only. Individual installations may vary. 5. Use diesel compatible thread sealer when installing fittings with NPT threads. (Loctite® 545 Thread Sealer is diesel compatible.)

SAFETY GUIDELINES! CAUTION: Chock the vehicle’s tires to prevent rolling.

CAUTION: Disconnect the battery cables before proceeding with the AirDog® installation.

CAUTION: Wear safety glasses when operating power tools such as drills and

grinders or when using a punch or chisel. CAUTION: Do Not drill into or weld the top of the frame rail or within 1 ½” of the

frame rail flange on the side of the frame rail. CAUTION: Route the fuel lines and electrical harnesses keeping them away

from hot exhaust components and/or moving parts. Properly secure the fuel lines and electrical harnesses to prevent chaffing.

If you are uncertain of any installation procedure, contact:

PureFlow® Technologies, Inc. for technical assistance. NOTE: The pictures used in this manual are for example only and may not depict the exact components as found on your truck.

6

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 3 Parts List

Installation Parts List QTY DESCRIPTION Part Number IMAGE

1 Installation Manual 206-1-0506

1

AirDog® FPII-200

2

Mounting Bracket 002-3C-0003

002-3C-0004 1 Hardware Kit, Includes:

4ea 3/8” x 1-1/2” Hex Head Bolt, 4ea 3/8” Nut 4ea 3/8” Lock Washer 4 Socket Head Cap Screws, 1/4-20 x 2" Lg. 4 Lock Washers, 1/4” 4 Hex Nuts, 1/4-20

901-08-0100

1 Wiring Harness with Microprocessor,

Indicator Light & Dash Plate plus Grommet

5E-2-3370-12 201-3-0004

5J-1-1-04-2758 1

Fuel Pressure Sensor

5C-9-007

2 #10 - JIC Flare x 1/2” NPT Fitting 4A-1-01-10-08-B

2 #10 - 900 Swivel X JIC Flare Fitting 4A-2-04-10-10-S

ISX Return Line Kit Components

2 #6 JIC Flare x ¼ NPT Fitting 4A-1-01-A-C-SZ 1 16 mm Male ORB x 16 mm Female ORB x #6

JIC Air/Vapor Return Fitting

4A-1-01-C-4-SZ 012-00-001

1S-1-16mm-SZ 1U-2-1-112

1 #6 - 90º Swivel x Fuel Line End 4A-2-13-05-06-S 1 #6 - Swivel x Straight Fuel Line End 4A-1-13-06-06-S

1 7 ft Section DOT Air/Vapor Return Line 4C-1-02-05-002-7 PLEASE NOTE

Due to the many variables in components and arrangement of those components in the many different truck models, the AirDog® installation kit contains only the basic fuel fittings needed to install the AirDog® using existing fuel lines.

7

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 4 Selecting the Best Mounting Location

Selecting the Best Location to Mount the AirDog®

Installing the AirDog® at the proper location on the vehicle is most important. When deciding where to locate the AirDog®, the following points should be considered:

• Best relationship to the transfer pump and the original primary fuel filter location.

• Protection from the elements and road debris • Accessibility for service

CAUTION: DO NOT mount the AirDog® directly on the engine. Mounting the AirDog® directly on the engine will immediately VOID your AirDog® Warranty! When possible, mount the AirDog® in the same location as the original primary fuel filter. The following examples, Figures 2 thru 5, show different AirDog® installations. There are many variations in the arrangements and the components on the various trucks. With a little ingenuity, the AirDog® can be successfully installed on any class 8 truck. Figure 2 shows the original fuel filter mounted on a bracket to the rear of the engine compartment and just above the frame behind the steering column. FIGURE 2 FIGURE 3

Figure 3 shows the primary fuel filter mounted on the frame.

8

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 4 Selecting the Best Mounting Location

Selecting the Best Mounting Location, cont’d In Figure 4, the AirDog® is mounted on the original fuel filter bracket high above the frame and toward the front of the engine compartment.

FIGURE 4 FIGURE 5 The installation in figure 5, a short nose “Day Cab” shows the AirDog® mounted on the frame on the driver’s side, behind the battery box.

Section 5: Mounting AirDog® ON THE TRUCK’S FRAME! NOTE: Do Not mount the AirDog® on the engine! Mounting the AirDog® on the engine will immediately void the AirDog® warranty. Mount the AirDog® on

the truck frame.

5-1. Remove the original primary fuel filter from the vehicle.

FIGURE 6

FIGURE 7 5-2. Hold the AirDog® with the brackets and filters attached next to the frame, check for clearance. FIGURE 8 FIGURE 9 5-3. Turn the steering wheel fully to the left and to the right to check for tire clearance.

9

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 5 Mounting the AirDog®

Mounting THE AirDog® On the Frame, cont’d! 5-4. Mark and center punch each hole location.

FIGURE 10 FIGURE 11 5-5. Drill a 3/8” hole at each of the 4 previously marked locations. WARNING! DO NOT DRILL INTO OR DAMAGE ANY WIRING, AIR LINES OR OTHER COMPONENTS LOCATED BEHIND THE FRAME RAIL. 5-6. Loose assemble the mounting brackets and AirDog® to the frame.

FIGURE 11

FIGURE 12 FIGURE 13

5-7. After mounting the AirDog® on the brackets, snug the fasteners to achieve a good relaxed fit, then finish tightening all of the fasteners. NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets due to vibration.

10

Field Serviceable Hose End Assembly Instructions: 1. Lubricate insert threads and I.D. of hose. 2. Screw hose into socket (left-hand thread) until hose bottoms. Back out 1/4 turn. 3. Screw insert into socket until insert touches socket.

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 5 Mounting the AirDog®

Mounting the AirDog® on the original filter bracket! 5-8. Remove the original fuel filter from the mounting bracket, (Example Figure 15.)

FIGURE 14 FIGURE 15 5-9. Attach the AirDog® mounting brackets to the original filter plate. If the original bracket is not wide enough to fit the AirDog® brackets, bolt an Optional Mounting Plate to the bracket. NOTE: PureFlow® Technologies has Optional Mounting Plate Kits available in the Parts and Accessories section of the AirDog® catalog.

FIGURE 16 FIGURE 17 5-10. Loose assemble the brackets to the plate and the AirDog® to the brackets. 5-11. After mounting the AirDog® on the brackets, snug the fasteners to achieve a good relaxed fit, finish tightening all of the fasteners. NOTE: These steps are necessary to prevent stress cracks from forming in the mounting brackets due to vibration.

11

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 6 Fuel Fittings Pressure Sensor & Lines

FUEL LINE OVERVIEW The AirDog® has been engineered to eliminate fuel related problems. It is important that the fuel lines are assembled and installed properly so as not to cause fuel flow restriction. When possible, use the fuel lines that are on the vehicle. This will reduce your installation costs and make the installation go much more quickly. NOTE: On various class 8 trucks, the manufacturer may use other than traditional steel braid fuel lines. These lines require special fittings. The fittings used with the original primary fuel filter are specific to the fuel lines used on the truck. When possible, mount the AirDog® in the location that will allow the use of the original fuel lines and fittings. Inspect the original fuel lines for size, length, and condition. If the fuel lines are in good condition and the correct size and length to adequately reach the AirDog®, you may want to go ahead and use them. If any of the fuel lines need to be replaced, it is recommended that the fuel lines selected meet or exceed DOT requirements. Fuel Supply Line: The fuel supply lines from the tank to the AirDog® and to the engine should be size 10 or, at the absolute minimum, size 8 (1/2” ID). Air/Vapor Return Line: The AirDog® Air/Vapor return line can be connected to the engine’s return line. A size 6 is adequate for the Air/Vapor return line. Primary Fuel Filters: It is most important that there are no fuel filters between the fuel tank and the AirDog® or between the AirDog® and the engine’s transfer pump to plug and cause restriction. These filters should be removed from the system as part of the AirDog® installation. Secondary Fuel Filters: DO NOT REMOVE SECONDARY FUEL FILTERS. This is the filter between the transfer pump and the engine.

Section 6A: Installing the Fuel Fittings and Low Fuel Pressure Sensor Switch! NOTE: Figures 18 & 19 illustrate the installation of straight fittings. However, in some instances 90º fittings may be required to connect the fuel lines to the AirDog®, Therefore, for your convenience two extra 90º fittings have been included in the kit. 6A-1. Install the straight #10 JIC x ½ NPT fuel fitting in the AirDog® fuel port marked

“ENGINE”. Use the 90º swivel fittings as needed when connecting the lines. FIGURE 18

FIGURE 19 6A-2. Install a straight #10 JIC x ½ NPT fuel fitting into the fuel inlet port next to the

regulator. Use the 90º swivel fittings as needed.

12


Section 6A: Installing the Fuel Fittings and Pressure Sensor Switch, cont’d!

6A-3. Install the ¼”NPT x #6 JIC Male Air/Vapor return fitting into the Air/Vapor return port marked “TANK”.

FIGURE 20

FIGURE 21

6A-4. Remove the 1/8” NPT plug in the AirDog® base. The plug is located just below

the motor end cap. Install the 450 elbow in this port. Install the pressure sensor switch into the elbow.

SECTION 6B: Installing the AirDog® Return Line

The AirDog® ISX SPECIAL RETURN FITTING Must Be Used for This Installation!

Signature 600 and ISX Electric Primer/Lift Pump Overview The early model of the Cummins Signature 600 did not have an electric Primer/Lift Pump. Because of hard start situations, Cummins adopted the use of an “Add On” electric primer pump or “Lift Pump” on the later model Signature engines. The “Lift Pump” was installed in the fuel supply line prior to the inlet to the engine and ran for approximately 2 minutes after the ignition switch is activated. When the ISX engine was developed, the electric primer/lift pump was built in to the bottom of the IFSM (Integrated Fuel System Module).

VERY IMPORTANT: The AirDog® Air/Vapor return line is connected directly to the Cummins Signature 600 and ISX engine fuel return line by means of the AirDog® Special Return Fitting. The AirDog® Special Return fitting serves multiple functions!

• The 16mm Male X 16mm Female X #6 “T” accommodates the AirDog® air/vapor return line on trucks equipped with either “Plastic” or Steel Braid Reinforced fuel lines.

• This fitting restricts engine return fuel flow to help boost the engine fuel pressure to 300 PSI for maximum efficiency. NOTE: Fuel Pressure Spec’s for the Cummins Signature 600 CM570 & ISX CM870 is 245 PSI to 320 PSI. Fuel Pressure Spec’s for the ISX CM871 is 245 PSI to 322 PSI.

• This fitting also enables the AirDog® Fuel Air Separation System to maintain a “Net Positive Pressure Head to the engine fuel transfer pump to overcome the affects of fuel filter plugging and high altitude operation.

VERY IMPORTANT: When the Ignition is activated, the ISX primer/Lift Pump will start to pump. The AirDog® will also start to pump. The two together can produce pressures of up to 45 PSI. This will immediately trigger a high pressure fault code. Therefore, the ISX primer/lift pump must be deactivated by unplugging the power lead.

13

AirDog® ISX Special Return Fitting


AirDog® Return Line

6B-1. Disconnect the engine fuel return line from the #8 JIC flare fitting located on the side of the engine and remove the original fuel return fitting. FIGURE 22 FIGURE 23

6B-2. Install the 16 mm ORB Male x 16 mm ORB Female x #6 JIC fitting, with the air/vapor return port, into the engine ‘fuel return port’. NOTE: This fitting installs between the engine and the original fuel return fitting and can be used for all Signature or ISX installations regardless of whether the vehicle is equipped with plasticor steel braid reinforced fuel lines. FIGURE 24

6B-3. Re-install the original return fitting into the new AirDog® Special ISX Return Fitting! 6B-4. Measure and cut a length of fuel line necessary to reach from the AirDog® Air/Vapor return fitting to the air/vapor return fitting in the fuel return “T”.

FIGURE 25 FIGURE 26 6B-5. Assemble the fuel line with the proper end fittings for the connections. NOTE: This assembled fuel line is for illustration only. Use the proper end fittings

that apply to your application! FIGURE 27 6B-6. Route and connect the Air/Vapor return line to the proper fittings on the AirDog®

and the return “T”. Properly tighten the fittings. Secure the fuel line as necessary to prevent abrasion and chaffing.

14

FUEL LINE from AirDog® TO ENGINE

FUEL LINE from TANK to AirDog®


SECTION 6: Connecting the AirDog® to the Engine and Tank 6C-1. Connect the engine fuel line that was originally connected to the fuel filter to the fitting in the AirDog® out to “Engine port. FIGURE 28 FIGURE 29

6C-2. Connect the fuel line from the tank to the fitting in the AirDog® fuel “IN” port. FIGURE 30 FIGURE 31

Connecting the AirDog® to the Engine and Tank on vehicles with plastic fuel lines!

6C-3. Remove the fittings for the plastic lines from the original filter assemblies and install them in their respective inlet and outlet ports in the AirDog®. 6C-4. Connect the fuel line to the engine to the AirDog® fuel outlet fitting. FIGURE 32

FIGURE 33 6C-5. Connect the fuel line from the tank to the AirDog® fuel inlet fitting.

15

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 7 Electrical Harness

ELECTRICAL HARNESS VERY IMPORTANT: The AirDog® electrical harness requires a MAXIMUM 15Amp Fuse!

The AirDog® wiring harness has a Microprocessor and two color LED indicator light as standard equipment.

VERY IMPORTANT: The LED Indicator Light will remain green until the first stage of filter plugging. It will then turn RED, indicating the fuel filter needs replacing. Then, if the filter is not timely changed, the light will begin flashing RED.

Additionally, should pressure flow to the engine drop below minimum requirements, the light will immediately begin flashing GREEN. First check the water separator. Then, check the screen in the water separator nipple. Clean or replace as necessary.

THE AIRDOG®, WIRING HARNESS. AirDog® Pump Motor Lead Pressure Sensor/Switch Lead Indicator Light & Lead Battery Positive Lead Battery Negative Lead

Relay Lead

FIGURE 34

Securing the Microprocessor to the Vehicle

7-1. Secure the Microprocessor to the vehicle. This picture shows the Microprocessor mounted next to the steering column.

FIGURE 35 FIGURE 36 7-2. Route the pump motor and indication light sensor lead to the AirDog®. Connect the 2 pin

Deutsch connector on the end of the wiring harness to the pump motor lead.

FIGURE 37 FIGURE 38 7-3. Connect the lead with the green seal to the “low fuel pressure” sensor switch.

16

By the Steering Column Under the Dash


Routing the Indicator Light Lead The Low Fuel Pressure Indicator Light lead must be routed through the firewall and to the Dash Board. The Relay Trigger Lead must be connected to a contact point that is electrically “HOT” when the starter key is in the “ON” position. This could be either in the engine compartment or inside the dash such as a spare fuse holder in the fuse panel or on the ignition switch itself. Note: DO NOT connect the relay lead to a point that is “HOT” when the starter key is in the ACCESSORY ON position.

Routing the Indicator Light and Relay Trigger Lead through the firewall:

7-4. Most Peterbilts and Kenworths have access holes located below the steering column. Remove the plug and route the leads through the hole.

FIGURE 39 FIGURE 40 7-5. For other make trucks, drill a 5/8" hole in firewall to allow entry of the Indicator Light

Lead into the cab. Use the grommet to seal around the loom cover.

FIGURE 41 FIGURE 42 7-6. Route the red relay trigger wire and indicator light lead through the firewall. NOTE: Be sure to seal the opening or install a grommet around the wire

loom to prevent water leakage and protection from chaffing.

17


INSTALLING THE FILTER MONITOR INDICATOR LIGHT. Two Color LED Indicator Light!

FIGURE 43 7-7. Select a location on the dash board that is easily visible to the driver. FIGURE 44 FIGURE 45 7-8. Remove the dash components as necessary to access the area behind the selected

location. 7-9. Drill a 9/16” hole at the selected location. Be very careful when drilling. Do not

damage components located behind the dash. Figure 46 Figure 47 7-10. Install the Dash Plate and Indicator Light in the dash. Connect the Indicator Light Lead to the connector on the wiring harness. 7-12. Re-install the removed dash components to their original position.

18


Connecting the Relay Trigger Lead!

The Relay Trigger Lead must be connected to a contact point that is “HOT” when the starter key is in the “ON” position. This could be either in the engine compartment or inside the dash such as a spare fuse holder in the fuse panel or on the ignition switch itself. Note: DO NOT connect the relay lead to a point that is “HOT” when the starter key is in the “ACCESSORY ON” position. 7-13. Crimp a proper “Connector” on the end of the Relay Trigger Lead. FIGURE 48

7-14. Connect the relay trigger lead to the “ON” or “RUN” terminal on the ignition switch.

CONNECTING THE POWER SUPPLY LEADS

The power supply leads can be easily connected to the appropriate contacts on the alternator. However, any high amperage terminal that is always “HOT” is OK for the Positive + (RED) lead. Be sure the NEGATIVE ▬ (BLACK) lead is connected to a reliable Chassis Ground.

7-15. Route the Red & Black power supply leads to the alternator. Connect the Black (-) ground lead to the alternator Ground connection.

FIGURE 49 FIGURE 50 7-16. Connect the Red (+) positive lead to the alternator Hot Lead going to the battery.

Ignition ON

Accessory

Battery

19

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 8 Initial Startup

SECTION 8: INITIAL START UP PROCEDURE The AirDog® is a self priming system. However, to prevent damage to a dry seal and reduce the life expectancy of the system, it is suggested to pre-fill the water separator/pre-filter with diesel fuel to the bottom of the “NUT PLATE”. 8-1. Pre-fill the water separator/pre-filter with diesel fuel up to the bottom of the nut plate. 8-2. Turn the starter key to the on/run position. 8-3. The AirDog® should now be running and pumping fuel, bleed the fuel line to the engine by loosening the fuel line connection at the engine fitting. As soon as the line is purged of air, tighten the fuel fitting. NOTE: Put a rag or shop towel around the fitting to prevent fuel splatter or spray. Catch all spilled fuel and dispose of properly. 8-4. Start your engine! 8-5. Check your Engine Fuel Pressure, See Section 9.

RECHECK ALL FUEL FITTINGS FOR LEAKS. BE SURE ALL LINES ARE PROPERLY SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY.

20

The port in the AirDog® Return Fitting is 0.130”

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 9 Fuel Rail Pressure

Cummins Signature 600 and ISX Fuel Rail Pressure

On startup, be sure that if the engine is equipped with an electric primer/lift pump (Fig. 53), the power supply lead has been disconnected. With the AirDog® and the OE primer/lift pump operating simultaneously, the combined pressure will throw a “high fuel pressure” code. The performance of the engine is defined by the CPL (Control Parts List) and the fuel system code. The fuel system calibration must be within published specifications.

Signature, ISX, and Qsx15 with CM870: Supply pump pressure is regulated at 1689 to2206 kPa (245 PSI to 320 PSI) at 2,100 RPM Signature, ISX, and Qsx15 with CM871: Supply pump pressure is regulated at 1689 to2220 kPa (245 PSI t0 322 PSI) at 2,100 RPM

For best engine performance, the fuel rail pressure should be 300 PSI at 2,100

Checking the engine fuel pressure FIGURE 51 Connect pressure gauge, Cummins part number 3375932, on the Compuchek™ fitting for Rail Fuel Pressure shown in Figure 53.

Read the rail fuel pressure at low idle and high idle. • Low idle 1586 to 1889 kPa (230 to 274 PSI) at 650 to 700 RPM • High idle 1896 to 2068 kPa (275 to 300 PSI) at 2,100 RPM

If the pressure is low, check pressure at the Fuel Pump Compuchek™ fitting. There should be no more than a 517 kPa (75 PSI) drop across the filter. If the pressure is low, it may be time for a clean filter. If the pressure is to high, the AirDog® Special Return “T” Fitting may need to be bored out to a slightly larger size to reduce the pressure! The Optimum Fuel Rail Pressure for best engine performance is 300 PSI

21

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 10 Fuel Filter & Pre-Filter

Servicing the AirDog Fuel Filter and Water Separator/Prefilter The AirDog® Microprocessor monitors the fuel filter and water separator !

FUEL FILTER: Plugging of the fuel filter will cause the AirDog® Indicator Light to go from GREEN to RED. Failure to timely service the fuel filter will cause the light to change from RED to FLASHING RED. Replace the fuel filter as necessary!

It is recommended to replace the fuel filter at 25,000 miles of service OR when the Indicator Light turns RED, which ever comes first!

When replacing the fuel filter, be sure to clean the under side of the AirDog® base. It is not necessary to pre-fill the fuel filter with fuel, the AirDog® will fill the filter and prime the system automatically. Follow the instructions on the filter for proper tightening procedures.

Figure 52

The Water Separator/Pre-filter

WATER SEPARATOR: Should the water separator/pre-filter or the wire screen in the nipple become plugged, preventing sufficient operating pressure flow to the engine, the Indicator Light will immediately change from GREEN to FLASHING GREEN.

Check the water separator/pre-filter for plugging. Clean or Replace as necessary! If the light continues to FLASH GREEN, check the screen in the water separator/pre-filter nipple for debris and plugging. Clean as necessary!

Replace the water separator if it becomes damaged or permanently plugged. Servicing of the water separator simply requires draining at regular intervals. It is suggested to check/drain the water separator weekly or as needed should you experience excessive ‘water in fuel’ conditions. Before re-installing the water separator after cleaning, be sure to clean the under side of the AirDog® base. Follow the instructions printed on the water separator/pre-filter for proper tightening procedures. DO NOT over tighten and damage the water separator with a filter wrench.

Caution: Be careful to prevent any contaminates or debris from entering the water separator when remove it for cleaning! Even though the water separator/pre-filter nipple has a protective wire screen, debris could jam the Gerotor and cause the fuse to blow. This is not a warranty item. Should this happen, it is easily put back into working order. See the instructions on “How to R & R the Gerotor” for proper cleaning procedures.

Dispose of waste fuel and used filters properly to protect OUR environment!

AirDog® Fuel Filter

Prefilter/Water Separator With Drain Valve

Pre-filter Nipple with Wire Screen

(1 1/8th Inch Hex)

22

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 11 Gerotor & Pump Assembly

Cleaning Debris from the Gerotor Assembly Step 1 Step 2 Step 3

Remove the four (4) socket Carefully remove the O-rings, Remove and clean the gerotor. head cap crews that secure you will need to re-use them. Be very careful not to the gerotor cap. damage the gerotor. Step 4 Step 5 Step 6 Remove the O-rings and clean Replace the center gear. Align and install the outer the inside of the gerotor pocket. gear and O-rings. Step 7 Step 8 1 4 3 2 Install the gerotor cap. Be very Loose assemble the cap screws. careful not to dislodge or pinch Torque the cap screws in an the O-rings. opposing pattern. NOTE: Should any installation problems arise, please call, toll free 1-877-463-4373 or 1-573-635-0555, for assistance Monday – Friday, 8:00 AM –4:30 PM CST.

23

PureFlow® Technologies, Inc. AirDog® FPII-200 Cummins Signature 600 & ISX Section 12 Pressure Regulator

How to Remove and Re-install the Pressure Regulator! The Adjustable Pressure Regulator is made of all stainless steel components, except for the viton O’rings.

A - Adjustor Screw B - Jam Nut C - Base Nut FIGURE 53 D - Spring E - Plunger F - Plunger O’ring :

A

B C D E

Regulator Components

STEP 1 STEP 2 STEP 3

Loosen Jam Nut “B” and regulator base nut “C”.

Turn Adjustor Screw “A” Counter clockwise to remove the assembly.

Remove the Adjustor Assembly from the AirDog® base. Be careful to not damage the O’rings or lose the regulator spring or plunger.

STEP 4 STEP 5 STEP 6

Be sure the Regulator Plunger and Spring are properly positioned, then carefully insert the Adjustor Assembly into the base. Turn the assembly clockwise until the base nut is flush with the surface of the AirDog® base.

Tighten the Base Nut. Re-adjust the output pressure by turning the Adjustor Screw counter clockwise until it stops against the Base Nut. Then, turn the adjuster screw in (Clockwise) 3 Turns. NOTE: Units built before December 1, 2013 require 5 turns.

F

24

Copyright © 2014 Bulletin No. 206-1-0506 CD Patents, LLC Revised January, 2014

All Rights Reserved

Cummins ISX Installation Manual Jan 2014 - airdogdiesel.com · 4G-HD FUEL PUMP, is a premium fuel filtration and delivery system for the Cummins ISX and Signature 600 Diesel Engines.

Documents